Method for fabricating absorbent articles

ABSTRACT

The present invention relates to a method for fabricating absorbent article having multiple layers, and deformed zones of targeted performance, and colored regions, the method comprising the steps of forming discrete features on at least one layer, printing colored regions on at least one layer, integrating multiple layers to form an absorbent assembly, and cutting the absorbent assembly into individual absorbent articles, wherein the steps are carried out continuously.

FIELD OF THE INVENTION

The present invention relates to methods for fabricating absorbentarticles. Specifically, the method can be used to fabricate absorbentarticles having a colored region and a deformed topsheet in a continuousprocess.

BACKGROUND OF THE INVENTION

Absorbent articles such as sanitary napkins and female adultincontinence articles that function to collect fluid discharged from awoman's vagina or urethra often include a deformed surface region and acolored region in the absorbent article.

A colored region on or below a top surface of an absorbent article thatis visible through a topsheet can provide functional and perceptionaladvantages. The colored region can overcome a problem of unsightlystaining during, for example, a woman's menstrual period. The coloredregion on a layer below the topsheet, which can be viewed through thetopsheet, can also provide for a perception of depth and greater fluidstorage capacity within the absorbent article. In addition, by includinga colored region in the central portion of the absorbent article,manufacturers of absorbent articles may effectively teach consumers thatthe central portion of the absorbent article is where the fluidcollected should reside.

Meanwhile, various fluid handling demands on different portions of anabsorbent article, different physical interactions between portions ofan absorbent article and portions of a wearer's body, and differentmoisture and chemical environments of different portions of a wearer'scrotch region create unique needs for different regions of the topsheet.Some absorbent articles designed to have a topsheet with deformedregions that are arranged to provide fluid handling benefits whereneeded and/or skin comfort benefits where needed are, for example,disclosed in WO 10/17360; WO 10/17362; and WO 10/17351.

Provision of a colored region and/or deformed regions on a web has beencarried out separately from an absorbent article fabrication.

In many cases to provide best functionality of absorbent articles, it isbest to provide each step of the manufacturing process next to eachother and in the right sequence so that one does not have issues withperformance of the absorbent articles that could occur if madeseparately. For instance, formation of features in a topsheet far apartor in a different sequence may cause weakening of the topsheetstructure, thereby causing tearing in use or during the manufacturingprocess. Further, separation of unit steps of feature formations mayincrease the possibility that some or many features closely co-locatedin a topsheet formed in different unit steps overlap which leads toincreased aperture size which would cause rewet problems.

Accordingly, there is a need for a process which can provide zones oftargeted performance, and colored regions in a high-speed continuousoperation.

SUMMARY OF THE INVENTION

The present invention is directed to a method for fabricating absorbentarticle having multiple layers, deformed zones of targeted performance,and colored regions, the method comprising the steps of forming discretefeatures on a topsheet, printing a colored region on at least one layer,integrating multiple layers to form an absorbent assembly, and cuttingthe absorbent assembly into individual absorbent articles, wherein thesteps are carried out continuously.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a process of the presentinvention.

FIG. 2 is a schematic representation of another embodiment of a processof the present invention.

FIG. 3 is a schematic representation of another means of forming firstdiscrete features in a process of the present invention.

FIG. 4 is a schematic representation of an exemplary process forselectively aperturing a web in the process of the present invention;

FIG. 5 is an enlarged perspective illustration of a web weakeningarrangement of the process of FIG. 4.

FIG. 6 is an enlarged perspective illustration of an incrementalstretching system in the process of FIG. 4.

FIG. 7 is a schematic representation of another process for selectivelyaperturing a web in the process of the present invention;

FIG. 8 is an enlarged perspective illustration of another web weakeningarrangement of the process of FIG. 7.

FIG. 9 is a schematic representation of optional discrete extendedelements forming step of a process of the present invention.

FIG. 10 is a schematic representation of another embodiment of a processof the present invention.

FIG. 11A is a schematic representation of another means of forming firstand second discrete features in a process of the present invention.

FIG. 11B is a schematic representation of another means of forming firstand second discrete features in a process of the present invention.

FIG. 11C is perspective representation of an apparatus and a methodshown in FIG. 11A for forming first and second discrete features in aprocess of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The term “absorbent article”, as used herein, includes disposablearticles such as sanitary napkins, panty liners, diapers, adultincontinence articles, and the like. Such absorbent articles areintended for the absorption of body liquids, such as menses or blood,vaginal discharges, urine, and feces. Various absorbent articlesdescribed above will typically comprise a liquid permeable topsheet, aliquid impermeable backsheet joined to the topsheet, and an absorbentcore between the topsheet and backsheet.

The term “aperture”, as used herein, refers to a hole. The apertures caneither be punched cleanly through the web so that the materialsurrounding the aperture lies in the same plane as the web prior to theformation of the aperture, or holes formed in which at least some of thematerial surrounding the opening is pushed out of the plane of the web.In the latter case, the apertures may resemble a protrusion ordepression with an aperture therein.

The term ‘color’ as referred to herein includes any color, i.e., white,black, red, blue, violet, orange, yellow, green, and indigo as well asdifferent shades thereof or mixtures thereof.

The term “component” of an absorbent article, as used herein, refers toan individual constituent of an absorbent article such as a topsheet,acquisition layer, liquid handling layer, absorbent core or layers ofabsorbent cores, backsheets, and barriers such as barrier layers andbarrier cuffs, and functional or aesthetic design elements such ascolored regions, channels, and features formed on a topsheet.

The term “comprising”, as used herein and in the claims, is inclusive oropen-ended and does not exclude additional unrecited elements,compositional components, or method steps.

The term “discrete”, as used herein, means distinct or unconnected. Whenthe term “discrete” is used relative to forming elements on a formingmember, it is meant that the distal (or radially outwardmost) ends ofthe forming elements are distinct or unconnected in all directions,including in the machine and cross-machine directions (even though basesof the forming elements may be formed into the same surface of a roller,for example).

The term “forming elements”, as used herein, refers to any elements onthe surface of a forming member such as a roller that are capable ofdeforming a web. The term “forming elements” includes both continuous ornon-discrete forming elements such as the ridges and grooves on ringrolls, and discrete forming elements.

The term “joined”, as used herein, refers to the condition where a firstcomponent is affixed, or connected, to a second component eitherdirectly; or indirectly, where the first component is affixed, orconnected, to an intermediate component which in turn is affixed, orconnected, to the second component. The joined condition between thefirst component and the second component is intended to remain for thelife of the absorbent article.

The term “machine direction” or “MD”, as used herein, refers to the paththat material, such as a web, follows through a manufacturing process,while the term “cross machine direction” or “CD” is the directionsubstantially perpendicular to the MD and in the plane generally definedby the web. Directions within 45 degrees of the cross direction areconsidered to be cross directional.

The term “nonwoven”, as used herein, refers to a material having astructure of individual fibers or threads which are interlaid, but notin a repeating pattern as in a woven or knitted fabric, which do nottypically have randomly oriented fibers. Nonwoven has been formed frommany processes, such as, for example, meltblowing processes, spunbondingprocesses, hydroentangling, and bonded carded web processes, includingcarded thermal bonding. The constituent fibers of a nonwoven can bepolymer fibers, and can be monocomponent, bicomponent, and/orbiconstituent, and a mixture of different fiber types.

The term “odor control composition”, as used herein, refers to suchcompositions usually contain, sometimes along with conventional perfumeingredients, ingredients which are able to chemically react with themalodorant molecules released from the body fluids (such as ammonia)thus neutralizing the source of the malodor, and/or ingredients whichare able to interact with nose receptors so that their perception of themalodorant molecules is reduced.

The term “phase”, as used herein, refers to the positional relationshipbetween two or more parts of a machine that performs repetitive motion.For example, phase may refer to the relative position of a punch thatstamps apertures into a component used in the manufacturing process.When utilized as verbs, the terms “phasing,” “phased,” “phase,” and thelike refer to the the act of changing the phase of a device from onephase to another. For example, the act of phasing a roller may refer toadvancing or retarding the rotation of the roller about its primaryaxis.

The term “polymer” generally includes, but is not limited to,homopolymers, copolymers, such as for example, block, graft, random andalternating copolymers, terpolymers, etc., and blends and modificationsthereof. In addition, unless otherwise specifically limited, the term“polymer” includes all possible geometric configurations of thematerial. The configurations include, but are not limited to, isotactic,atactic, syndiotactic, and random symmetries.

The term “tuft”, as used herein, refers to a particular type ofprotrusion. Tufts may have a tunnel-like configuration, and in somecases may be open at one or both of their ends.

The term “upper”, as used herein, refers to absorbent members, such aslayers, that are nearer to the wearer of the absorbent article duringuse, i.e. towards the topsheet of an absorbent article; conversely, theterm “lower” refers to absorbent members that are further away from thewearer of the absorbent article towards the backsheet.

The term “web”, as used herein, refers to any suitable deformablematerial, such as a woven, nonwoven, film, combination, or laminate ofany of the foregoing materials.

Absorbent Article

Absorbent articles manufactured by a method according to the presentinvention comprise a liquid permeable deformed topsheet; a liquidpermeable colored sheet, and a liquid impermeable backsheet joined tothe topsheet, wherein the topsheet comprises a first layer and a secondlayer, and have a plurality of first discrete features; wherein thecolored sheet has a first colored region and comprises a colored sheetweb; and wherein the backsheet comprises a backsheet web. In oneembodiment, the topsheet further comprises a plurality of seconddiscrete discrete features.

Each of the first layer and the second layer can be a polymer film, anonwoven, a composite comprising a polymer film or a nonwoven, orlaminate comprising a polymer film or a nonwoven. In one embodiment, thefirst layer is a first polymer film and the second layer is selectedfrom a nonwoven and a second polymer film. In the embodiment the firstpolymer and second polymer films may be the same or different polymerfilms. In another embodiment, the first layer is a first nonwoven andthe second layer is selected from a polymer film and a second nonwoven.In this embodiment, the first and the second nonwovens may be the sameor different materials.

In one embodiment, when at least one of the first and second layers is apolymer film, the the polymer film is a polymer film including materialsnormally extruded or cast as films such as polyolefins, nylons,polyesters, and the like. Such films can be thermoplastic materials suchas low density polyethylene, medium density polyethylene, high densitypolyethylene, linear low density polyethylene, polypropylenes andcopolymers and blends containing substantial fractions of thesematerials.

The polymer film can have a plurality of discrete extended elements.Patent publications disclosing such a plurality of discrete extendedelements include WO 01/76842; WO 10/104996; WO 10/105122; WO 10/105124and US20120277701A1. In one embodiment, the polymer film can have aplurality of discrete extended elements comprising open proximal ends,open or closed distal ends, and sidewalls, wherein the discrete extendedelements comprise thinned portions at the distal ends of the discreteextended elements and/or along the sidewalls of the discrete extendedelements, and wherein the discrete extended elements have a diameter ofless than about 500 microns; the discrete extended elements have anaspect ratio of at least about 0.2; and/or the polymer film comprises atleast about 95 discrete extended elements per square centimeter.

In another embodiment, when at least one of the first and second layersis a nonwoven, the nonwoven constituting the topsheet is a colorednonwoven.

In the present invention, the colored sheet comprising a colored sheetweb may function as a secondary topsheet in an absorbent article. Thecolored sheet web can be any sheet material that allows a colored regionto be readily seen from a body-facing surface of an absorbent article,and can be manufactured from a wide range of materials such as woven,nonwoven materials, latex or thermally bonded airlaid materials,polymeric materials such as apertured formed thermoplastic films,apertured plastic film, hydro formed thermoplastic films, porous foams,reticulated foams, reticulated thermoplastic films and thermoplasticscrims.

In the present invention, a backsheet web can be any backsheet materialcommonly used for absorbent articles such as polyolefinic films likepolyethylene, polypropylene and a combination thereof. In someembodiments, the backsheet may be impervious to malodorous gasesgenerated by absorbed bodily discharges, so that the malodors do notescape. The backsheet may or may not be breathable.

An absorbent article manufactured by the method according to the presentinvention has a background region and a first colored region, andoptionally a second colored region being viewable from the body-facingsurface of the absorbent article. The background region is visuallydistinguishable from the first colored region and the optional secondcolored region. The background region can be white or any other colorvisually distinguishable from the first colored region and secondcolored region. The first colored region and the optional second coloredregion can be visually distinguishable in terms of color and/or shade ofa color. Colors are believed to be visually distinguishable if there isa ΔE calculated according to the equation below between the two colorsof at least about 1. The first colored region and the second coloredregion, respectively, can have multiple colored regions. The multiplecolored regions can be visually distinguishable in terms of color and/orshade of a color.

The color of the first colored region, the second colored region andbackground region are measured by the reflectance spectrophotometeraccording to the method disclosed in WO 11/25486. The difference incolor is calculated using the L*, a*, and b* values by the formulaΔE=[(L*_(X.)−L*_(Y))²+(a*_(X.)−a*_(Y))²+(b*_(X)−b*_(Y))²]^(1/2). Herein,the ‘X’ in the equation may represent the first colored region, thesecond colored region or the background region, and ‘Y’ may representthe color of another region against which the color of such region iscompared. X and Y should not be the same two points of measurement atthe same time.

The absorbent articles of the present invention may further comprise anabsorbent core joined with the topsheet, the backsheet, or both in anymanner as is known by attachment means such as those well known in theart. Embodiments of the present invention are envisioned whereinportions of the entire absorbent core are unattached to either thetopsheet, the secondary topsheet, the backsheet, or more than one ofthese layers. The absorbent core can be formed from any of the materialswell known to those of ordinary skill in the art. Examples of suchmaterials include multiple plies of creped cellulose wadding, fluffedcellulose fibers, wood pulp fibers also known as airfelt, textilefibers, a blend of fibers, a mass or batt of fibers, airlaid webs offibers, a web of polymeric fibers, and a blend of polymeric fibers.Other suitable absorbent core materials include absorbent foams such aspolyurethane foams or high internal phase emulsion (“HIPE”) foams.Suitable HIPE foams are disclosed in U.S. Pat. No. 5,550,167, U.S. Pat.No. 5,387,207, U.S. Pat. No. 5,352,711, and U.S. Pat. No. 5,331,015. Theabsorbent core can comprise superabsorbent materials such as absorbentgelling materials (AGM), including AGM fibers, as is known in the art.

The absorbent articles of the present invention may have a pair of flapson longitudinal sides of a body-facing surface for folding around andsecuring the absorbent article to the undergarment, the flaps comprisingthe first layer and the backsheet. Alternatively, the flaps can comprisethe first layer, the second layer, and the backsheet. The layers in theflaps can be laminated by either adhesive or thermally bonded means,where thermal bonding includes but is not restricted to technologiessuch as ultrasonic bonding, cold pressure bonding, and hot pressurebonding. The flaps may have a plurality of third discrete featuresthereon. The third discrete features may be the same as or differentfrom the first discrete features or the optional second discretefeatures. In one embodiment, the plurality of third discrete featurescan be formed simultaneously with the plurality of first discretefeatures. In another embodiment where the topsheet further comprises aplurality of second discrete features, the plurality of third discretefeatures can be formed simultaneously with the plurality of seconddiscrete features. For a plurality of third discrete features may bedepressions formed toward a garment facing side of a topsheet. In oneembodiment, depression type of third discrete features can be formedsimultaneously with a plurality of first discrete features when theplurality of first discrete features are apertures toward a garmentfacing side of a topsheet.

The invention is applicable to the production of absorbent articles fromdiscrete components, and it is particularly advantageous for theproduction of absorbent articles from at least one continuous sheet orweb.

A schematic representing a method according to the invention is depictedin FIG. 1. In FIG. 1, the machine direction is from left to right. Themethod of the invention may form the absorbent article upside down.Alternatively, the absorbent article can be formed top-side up.

The process 1 carried out according to the example in FIG. 1 comprisessupplying a second layer 12 onto a first layer 11 to form a composite 31of the first layer 11 and the second layer 12, feeding the composite 31to a first discrete feature forming unit 211 to form a first deformedcomposite 32. Though the process shown in FIG. 1 indicates a step ofcomposite formation and a step of first discrete features formation arecarried out sequentially, these two steps can be carried outsimultaneously as shown in FIG. 3.

In one example, the first discrete feature forming units 211 maycomprise a pair of two generally cylindrical rollers wherein at leastone of the two rollers has discrete feature forming elements on itssurface. In another example when the first discrete features areapertures, the first discrete feature forming units 211 may comprise ameans for weakening a web, composite 31 in this case, at a plurality oflocations to create a plurality of weakened, melt-stabilized locations,and a means for applying a tensioning force to the composite 31 torupture the composite 31 at the plurality of weakened, melt-stabilizedlocations creating a plurality of apertures in the composite 31coincident with the plurality of weakened, melt-stabilized locations.Referring to FIGS. 4 and 7, a means for weakening web at a plurality oflocations to create a plurality of weakened may be a web weakeningroller arrangement 108 or 308, and a means for applying a tensioningforce to the web to rupture the web at the plurality of weakened may bea incremental stretching system 132 or 332 shown in FIGS. 4 and 7.

Separately, a colored sheet web 13 is provided with a first coloredregion in a first coloration unit 231, and then is supplied onto asecond layer side of the first deformed composite 32. When the coloredsheet web 13 already has a first colored region before conducting thefirst coloration step, the first coloration step may be skipped, orstill employed to provide an additional colored region on the coloredsheet web 13. Then, the colored sheet web 13 and the first deformedcomposite 32 are integrated to form an integrated composite 34 in anintegration unit 251. And then, a backsheet web 15 is supplied onto acolored sheet web side of the integrated composite 34 and integrated byperipheral sealing along a peripheral line of an absorbent article in aperipheral seal unit 261 to form an absorbent article assembly 36. Theabsorbent article assembly 36 is cut in a cutting unit 271 intoindividual absorbent articles 37.

Referring to FIG. 2, there is shown another example of a methodaccording to the invention with several optional steps. In the process 2carried out in FIG. 2, initially a first layer 11 is produced with asecond colored region in a second coloration unit 241. The secondcolored region can be provided on either side of the first layer 11.Alternatively, the second colored region can be provided in a secondlayer 12. When the first layer 11 or the second layer 12 already has asecond colored region before conducting the second coloration step, thesecond coloration step may be skipped, or still employed to provideadditional colored region on the first layer 11 or the second layer 12.The second layer 12 is supplied onto the colored first layer 40 to forma composite 41 of the colored first layer 40 and the second layer 12,the composite 41 is fed into a first discrete feature forming unit 211to form a first deformed composite 42, and the first deformed composite42 is fed into a second discrete feature forming unit 221 to form asecond deformed composite 43. A step of forming the composite 41 and astep of forming the first discrete features can be carried outsequentially as illustrated in FIG. 2 or simultaneously as shown in FIG.3.

In one example, the first and second discrete feature forming units 211and 221, respectively, may comprise a pair of two generally cylindricalrollers wherein at least one of the two rollers in each unit hasdiscrete feature forming elements on its surface.

In another example, when the first discrete features are apertures, thefirst discrete feature forming units 211 may comprise a means forweakening a web, composite 41 in this case, at a plurality of locationsto create a plurality of weakened, melt-stabilized locations, and ameans for applying a tensioning force to the composite 41 to rupture thecomposite 41 at the plurality of weakened, melt-stabilized locationscreating a plurality of apertures in the composite 41 coincident withthe plurality of weakened, melt-stabilized locations. Referring to FIGS.4 and 7, a means for weakening web at a plurality of locations to createa plurality of weakened may be a web weakening roller arrangement 108 or308, and a means for applying a tensioning force to the web to rupturethe web at the plurality of weakened may be a incremental stretchingsystem 132 or 332 shown in FIGS. 4 and 7.

Then, the colored sheet web 13 is supplied onto a second layer side ofthe second deformed composite 43. The colored sheet web 13, before beingsupplied onto the second deformed composite 43 to form an integratedcomposite 44, is provided with a first colored region in a firstcoloration unit 231, and may be cut into a predetermined size and shape,then is supplied onto a second layer side of the second deformedcomposite 43. When the colored sheet web 13 already has a first coloredregion before conducting the first coloration step, the first colorationstep may be skipped, or still employed to provide additional coloredregion on the colored sheet web 13. Then, the second deformed composite43 and the colored sheet web 13 are integrated to form an integratedcomposite 44, and an absorbent core 14, which can be a continuous sheetor in a determined size and shape, is supplied onto a colored sheet webside of the integrated composite 44 to form a core layered composite 45.A backsheet web 15 is supplied and adhered onto the absorbent core sideof the core layered composite 45, and integrated by peripheral sealingalong a peripheral line of an absorbent article in a peripheral sealunit 261 to form an absorbent article assembly 46. The absorbent articleassembly 46 is then cut by a cutting unit 271 into individual absorbentarticles 47.

The first layer 11 can have a plurality of discrete extended elementswhich may be formed in a step continuously proceeding with a methodaccording to the invention. Formation of a plurality of discreteextended elements can be carried out prior to formation of a pluralityof first discrete features. Referring to FIG. 9, the first layer 11 isfed into a discrete extended elements forming unit 281 to form aplurality of discrete extended elements before forming a first deformedcomposite 52. Examples of the discrete extended elements forming unit281 and discrete extended elements forming processes are disclosed in WO10/105009; WO 10/105002; WO 10/105017; WO 11/112213; and WO 12/148936.

Referring to FIG. 10, there is shown another example of a methodaccording to the invention. The process 3 carried out according to theexample in FIG. 10 comprises feeding a laminate 61 comprising a firstlayer and a second layer to a first discrete feature forming unit 211 toform a first deformed laminate 62. Following steps may be conductedaccording to the process of the example of FIG. 1 or FIG. 2. When thefollowing steps is conducted according to FIG. 1, a colored sheet web 13is provided with a first colored region in a first coloration unit 231,and then is supplied onto a second layer side of the first deformedlaminate 62. When the colored sheet web 13 already has a first coloredregion before conducting the first coloration step, the first colorationstep may be skipped, or still employed to provide an additional coloredregion on the colored sheet web 13. Then, the colored sheet web 13 andthe first deformed laminate 62 are integrated to form an integratedlaminate 64 in an integration unit 251. And then, a backsheet web 15 issupplied onto a colored sheet web side of the integrated laminate 64 andintegrated by peripheral sealing along a peripheral line of an absorbentarticle in a peripheral seal unit 261 to form an absorbent articleassembly 66. The absorbent article assembly 66 is then cut in a cuttingunit 271 into individual absorbent articles 67. The process according toFIG. 10 may comprise a step of providing a second colored region oneither the first layer side or the second layer side of the laminate 61prior to the step of forming the first discrete features on the laminate61. The process according to FIG. 10 may further comprise at least oneof the optional steps described in respect with FIG. 2.

In the examples above, the first and second discrete feature formingunits 211 and 221, respectively, may comprise two generally cylindricalrolls wherein at least one of the two rolls in each unit has discretefeature forming elements on its surface.

In another example, when the first discrete features are apertures, thefirst discrete feature forming units 211 may comprise a means forweakening a web, a laminate 61 comprising a first layer and a secondlayer in this case, at a plurality of locations to create a plurality ofweakened, melt-stabilized locations, and a means for applying atensioning force to the laminate 61 to rupture the laminate 61 at theplurality of weakened, melt-stabilized locations creating a plurality ofapertures in the laminate 61 coincident with the plurality of weakened,melt-stabilized locations. Referring to FIGS. 4 and 7, a means forweakening web at a plurality of locations to create a plurality ofweakened may be a web weakening roller arrangement 108 or 308, and ameans for applying a tensioning force to the web to rupture the web atthe plurality of weakened may be a incremental stretching system 132 or332 shown in FIGS. 4 and 7.

Formation of First Discrete Features and Optional Second DiscreteFeatures

In the present invention, the first discrete features and the optionalsecond discrete features may be of any suitable configuration. Suitableconfigurations for the features include, but are not limited to:apertures; ridges (continuous protrusions) and grooves (continuousdepressions); tufts; columnar shapes; dome-shapes, tent-shapes,volcano-shapes; features having plan view configurations includingcircular, oval, hour-glass shaped, star shaped, polygonal, polygonalwith rounded corners, and the like, and combinations thereof. Polygonalshapes include, but are not limited to rectangular (inclusive ofsquare), triangular, hexagonal, or trapezoidal. In one embodiment, thefirst discrete features are features selected from the group consistingof apertures, protrusions, depressions, tufts, and combinations thereof,and the second discrete feature are features selected from the groupconsisting of apertures, protrusions, depressions, tufts, andcombinations thereof. In another embodiment where the topsheet furthercomprises second discrete features, the first discrete features areapertures and the second discrete features are tufts.

The first discrete features and the second discrete features may differfrom each other in terms of one or more of the following properties:type, shape, size, aspect ratio, edge-to-edge spacing, height or depth,density, color, surface treatment (e.g., lotion, etc.), number of weblayers within the features, and orientation (protruding from differentsides of the web). The term “type”, as used herein, refers to whetherthe feature is an aperture, a protrusion such as a tuft and other kindof protrusion, or a depression. In the present invention, discretefeatures may be of any suitable size. Typically, either the firstfeatures or the optional second feature may be macroscopic. In someembodiments, the first features and the second features may both bemacroscopic. The plan view area of the individual features may, in someembodiments of the web, be greater than or equal to about 0.5 mm², 1mm², 5 mm², 10 mm², or 15 mm², or lie in any range between two of thesenumbers. The methods described herein can, however, be used to createfirst features and/or second features that are microscopic which haveplan view areas less than 0.5 mm².

Various methods and apparatuses for deforming webs by forming discretefeatures on webs known in the art can be utilized to form the first andthe optional second discrete features in the present application.Patents disclosing such methods include: U.S. Pat. No. 4,189,344; U.S.Pat. No. 4,276,336; U.S. Pat. No. 4,609,518; U.S. Pat. No. 5,143,679;U.S. Pat. No. 5,562,645; U.S. Pat. No. 5,743,999; U.S. Pat. No.5,779,965; U.S. Pat. No. 5,998,696; U.S. Pat. No. 6,332,955; U.S. Pat.No. 6,739,024; US Patent Application Publication 2004/0110442 A1; EP 1440 197 B1; U.S. Pat. No. 6,916,969; US Patent Application PublicationNo. 2006/0151914 A1; U.S. Pat. No. 7,147,453; U.S. Pat. No. 7,423,003;U.S. Pat. No. 7,323,072; US Patent Application Publication No.2006/0063454 A1; US Patent Application Publication No. 2007/0029694 A1;US Patent Application Publication No. 2008/0224351 A1; US PatentApplication Publication No. 2009/0026651 A1; U.S. Pat. No. 7,521,588; USPatent Application Publication No. 2010/0201024 A1; WO2012/148980;WO2012/149074; WO2012/148935; and WO2012/148946.

One type of features preferred for discrete features in the presentinvention are apertures. Apertures in a topsheet in an absorbent articlemay enhance penetration of body exudates through the topsheet into theunderlying secondary topsheet or absorbent core. Various methods andapparatuses for forming apertures are disclosed in the patentliterature. Patents disclosing such methods include: U.S. Pat. No.8,241,543, U.S. Pat. No. 3,355,974; U.S. Pat. No. 2,748,863 and U.S.Pat. No. 4,272,473 disclosing aperture forming methods using apparatushaving heated aperture forming elements; U.S. Pat. No. 5,628,097disclosing a method for selectively aperturing a nonwoven web or alaminate by weakening the web at a plurality of locations; U.S. Pat. No.5,735,984 disclosing ultrasonic aperturing; U.S. Pat. Nos. 4,342,314 and4,463,045 disclosing vacuum aperturing; U.S. Pat. Nos. 4,609,518;4,629,643 and 4,695,422 disclosing hydroforming apertures; and U.S. Pat.No. 5,628,097 disclosing weakening a web along a plurality of locationsand then applying a tensioning force to the web causing the web torupture at the plurality of weakened location.

Referring to FIG. 4 there is schematically illustrated a process 100 forselectively aperturing a web. A web may be a composite comprising afirst layer and a second layer layer, or a laminate comprising a firstlayer and a second layer.

According to the present invention, a web 10 travels and passes througha nip 106 of the web weakening roller arrangement 108 formed by rollers110 and 112.

Referring to FIGS. 4 and 5, the web weakening roller arrangement 108preferably comprises a patterned calendar roller 110 and a smooth anvilroller 112. One or both of the patterned calendar roller 110 and thesmooth anvil roller 112 may be heated and the pressure between the tworollers may be adjusted by well known means to provide the desiredtemperature, if any, and pressure to concurrently weaken andmelt-stabilize the web 10 at a plurality of locations.

The patterned calendar roller 110 is configured to have a circularcylindrical surface 114, and a plurality of protuberances or patternelements 116 which extend outwardly from surface 114. The protuberances116 are disposed in a predetermined pattern with each protuberance 116being configured and disposed to precipitate a weakened, melt-stabilizedlocation in the web 10 to effect a predetermined pattern of weakened,melt-stabilized locations in web 10. As shown in FIG. 5, patternedcalendar roller 110 has a repeating pattern of protuberances 116 whichextend about the entire circumference of surface 114. Alternatively, theprotuberances 116 may extend around a portion, or portions of thecircumference of surface 114.

The protuberances 116 are preferably truncated conical shapes whichextend radially outwardly from surface 114 and which have ellipticaldistal end surfaces 117 although it is not intended to thereby limit thescope of the present invention to protuberances of only thisconfiguration. Other suitable shapes for distal ends 117 include, butare not limited to circular, square, rectangular, etc. The roller 110 isfinished so that all of the end surfaces 117 lie in an imaginary rightcircular cylinder which is coaxial with respect to the axis of rotationof roller 110. The protuberances 116 are disposed in a regularpredetermined pattern of rows and columns in the embodiment shown inFIG. 5, although it is not intended to thereby limit the scope of thepresent invention to the pattern of protuberances of only thisconfiguration. The protuberances may be disposed in any predeterminedpattern about patterned calendar roller 110.

Anvil roller 112 is preferably a smooth surfaced, right circularcylinder of steel.

Referring now to FIG. 6, there is shown a fragmentary enlarged view ofthe incremental stretching system 132 comprising incremental stretchingrollers 134 and 136. The incremental stretching roller 134 includes aplurality of teeth 160 and corresponding grooves 161 which extend aboutthe entire circumference of roller 134. Incremental stretching roller136 includes a plurality of teeth 162 and a plurality of correspondinggrooves 163. The teeth 160 on roller 134 intermesh with or engage thegrooves 163 on roller 136, while the teeth 162 on roller 136 intermeshwith or engage the grooves 161 on roller 134. As the web 10 havingweakened, melt-stabilized locations 202 passes through the incrementalstretching system 132 the web 10 is subjected to tensioning in the CD orcross-machine direction causing the web 10 to be extended in the CDdirection. Alternatively, or additionally the web 10 may be tensioned inthe MD or machine direction. The tensioning force placed on the web 10is adjusted such that it causes the weakened, melt-stabilized locations202 to rupture creating a plurality of apertures 204 coincident with theweakened melt-stabilized locations 202 in the web 10. However, the bondsof the web 10 are preferably strong enough such that they do not ruptureduring tensioning, thereby maintaining the web 10 in a coherentcondition even as the weakened, melt-stabilized locations rupture.However, it may be desirable to have some of the bonds rupture duringtensioning.

Other exemplary structures of incremental stretching mechanisms suitablefor incrementally stretching or tensioning the web are described in WO95/03765 the disclosure of which is incorporated herein by reference.

The web 10 is preferably taken up on wind-up roller 180 and stored.Alternatively, the web 10 may be fed directly to a production line whereit is used to form a topsheet on a disposable absorbent article.

Referring to FIG. 7 there is schematically illustrated at 300 anotherprocess for selectively aperturing a web. A web 10 is forwarded throughthe weakening arrangement 308, and passed directly through the weakeningarrangement 308.

Referring to FIGS. 7 and 8, the weakening arrangement 308 preferablycomprises an ultrasonic transducer 306 and a cylinder 310. As web 10 isforwarded between the ultrasonic transducer 306 and the anvil cylinder310, the web 10 is subjected to ultrasonic vibrational energy whereuponpredetermined pattern locations of the web 10 are weakened andmelt-stabilized. Anvil 310 has a multiplicity of discrete patternprotuberances which are generally designated 316 disposed on itsoutwardly facing surface 314 in a predetermined pattern which extendsabout the entire circumference of the anvil cylinder. The protuberances316 are disposed in a predetermined pattern with each protuberance 316being configured and disposed to precipitate a weakened, melt-stabilizedlocation 304 in the web 10 to effect a predetermined pattern ofweakened, melt-stabilized locations in the web 10. As shown in FIG. 8,anvil 310 has a repeating pattern of protuberances 316 which extendabout the entire circumference of surface 314. Alternatively, theprotuberances 316 may extend around a portion, or portions of thecircumference of surface 314.

The protuberances 316 are preferably truncated conical shapes whichextend radially outward from the surface 314 and which have ellipticaldistal end surfaces. Other suitable shapes for the distal end include,but are not limited to, circular, square, rectangular, etc. The anvil310 is finished so that all of the end surfaces lie in an imaginaryright circular cylinder which is coaxial with respect to the axis ofrotation of anvil 310.

After having passed through the weakening arrangement 308, and prior topassing through the nip 330 of the incremental stretching system 332,the web 10 includes a plurality of weakened, melt-stabilized locations304 which generally correspond to the pattern of protuberances 316extending from the surface 314 of anvil 310.

From the weakening arrangement 308, the web 10 passes through nip 330formed by the incremental stretching system 332 employing opposedpressure applicators having three-dimensional surfaces which at least toa degree are complementary to one another. The incremental stretchingsystem 332 preferably comprises incremental stretching rollers 334 and336. The incremental stretching roller 334 includes a plurality of teethand corresponding grooves which extend about the entire circumference ofthe roller 334. Incremental stretching roller 336 includes a pluralityof teeth and a plurality of corresponding grooves. Teeth on roller 334intermesh or engage with the grooves on roller 136, while the teeth onroller 336 intermesh with or engage with the grooves on the roller 334.As the web 10 having weakened, melt-stabilized locations 304 passesthrough the incremental stretching system 332, the web 10 is subjectedto tensioning causing the web 10 to be extended. The tensioning forceplaced on the web 10 is adjusted such that it causes the weakened,melt-stabilized locations 304 to rupture creating a plurality ofapertures in the web 10 which are coincident with the weakenedmelt-stabilized locations.

Another type of discrete features preferred in the present invention,especially when at least one of the first and second layers is nonwoven,are tufts. In many applications, it is desirable that fibrous webs havea bulky texture and/or softness. Composites or laminates comprising anonwoven in which nonwoven fibers protrude or are partially exposedthrough a polymer film or nonwoven can be useful as a topsheet inabsorbent articles as they provide an absorbent structure in which thenonwoven acts as the conveyor of fluid. As a non-limiting example, thecomposite or laminate comprises a polymer film and a nonwoven structuredsuch that the fluid collecting side of the composite or laminate is thepolymer film, and nonwoven fibers protrude or are partially exposedthrough the polymer film to the fluid collecting side.

Various methods and apparatuses for forming tufts disclosed in patentliterature. Patents disclosing such methods include: U.S. Pat. Nos.3,485,706, 4,465,726 and 4,379,799 disclosing forming tufts usingwaterjet; U.S. Pat. No. 4,741,941 disclosing forming tufts using airdrawing; U.S. Pat. No. 5,080,951 disclosing a needle punching method;and WO 1994/058117, WO 2004/59061, and WO 2010/117636 disclosing amethod for making tufts on a web using an apparatus comprising a rollercomprising a plurality of ridges and grooves.

In one embodiment, when both the first and second discrete features areformed by rolls, the first discrete features are formed by feeding acomposite 31, 41 of a first layer and a second layer, or a laminate 61comprising a first layer and a second layer in a machine direction intoa first nip that is formed between two generally cylindrical rolls, thetwo rolls having surfaces wherein at least one of the two rolls hasfirst discrete feature forming elements on its surface, and when thecomposite or laminate is fed into the nip, the composite or laminate isdeformed. The second discrete features are formed by feeding a firstdeformed composite 32, 42 or a first deformed laminate 62 in a machinedirection into a second nip that is formed between two generallycylindrical rolls, the two rolls having surfaces wherein at least one ofthe two rolls has second discrete feature forming elements on itssurface. The two rolls forming the first discrete features and the tworolls forming the second discrete features can be separate pairs ofrolls. When apertures as first or second discrete features are formedaccording to the method disclosed in U.S. Pat. No. 5,628,097, thecomposite 31, 41 or the laminate 61 is weakened at a plurality oflocations by for example heat and/or pressure prior to being fed into anip formed between two rolls.

In another embodiment when both the first and second discrete featuresare formed by rolls, the two rolls forming the first discrete featuresand the two rolls forming the second discrete features can share oneroller between the two pairs of rolls. As shown in FIG. 11A and FIG. 11Brespectively, the first discrete features are formed by feeding acomposite 41 of a first layer and a second layer, or a laminate 61comprising a first layer and a second layer in a machine direction intoa first nip 305 that is formed between a first generally cylindricalroller 301 and a second generally cylindrical roller 302, and a firstdeformed composite 42 or a first deformed laminate 62 is prepared.Continuously, the second discrete features are formed by introducing thefirst deformed composite 42 or the first deformed laminate 62 in amachine direction into a second nip 307 that is formed between thesecond generally cylindrical roller 302 and a third generallycylindrical roller 303, forming a second deformed composite 43 or asecond deformed laminate 63. Referring to FIG. 11C, there is shown inmore detail the portion of means of forming the first and seconddiscrete features shown in FIG. 11A that can form second deformedcomposite 43 having first and second discrete features. The particularplacement of the first discrete features and the second discretefeatures on the composite 41 can depend on, for example, the arrangementof the absorbent article in which the second deformed composite 43 willultimately be incorporated. For example, first discrete features may beformed into a region of the composite 41 which will be a central regionof an absorbent article, and second discrete features may be formed intoa region which will be an edge region surrounding the central region ofan absorbent article.

In the illustrated embodiment, the first discrete features 113 and thesecond discrete features 123 include structural modifications formed byurging discrete portions of the composite 41 in a first direction whileconcurrently urging other discrete portions of the first deformedcomposite 42 in a different, opposite direction. More specifically,apertures 113 are formed by rolls 301 and 302 urging discrete portionsof the composite 41 in a first direction and tufts 123 are formed byrolls 302 and 303 urging discrete portions of the first deformedcomposite 42 in a second direction. In the illustrated embodiment, thefirst and second directions generally extend extend in oppositedirections that are parallel to the Z-direction.

Each of rolls 301, 302 and 303 rotates about an axis A, the axis A beingparallel and in the same plane.

Roller 301 comprises a plurality of ridges 101 and corresponding grooves102 which extend unbroken about the entire circumference of roller 301.In some embodiments, depending on what kind of pattern is desired asfirst discrete features, roller 301 can comprises ridges 101 whereinportions have been removed, such as by etching, milling or othermachining processes, such that some or all of ridges 101 are notcircumferentially continuous, but have breaks or gap. The breaks or gapscan be arranged to form a pattern.

Rolls 302 and 303 can each comprise a plurality of ridges 101 andcorresponding grooves 102 which can extend unbroken about the entirecircumference of the corresponding roller. The roller 302 comprises aplurality of rows of circumferentially-extending ridges that have beenmodified to be rows of circumferentially-spaced teeth 111 that extend inspaced relationship about at least a portion of the correspondingroller. The individual rows of teeth 111 can be separated bycorresponding grooves 112. The roller 303 comprises a plurality of rowsof circumferentially-extending ridges that have been modified to be rowsof circumferentially-spaced teeth 121 that extend in spaced relationshipabout at least a portion of the corresponding roller. The individualrows of teeth 121 can be separated by corresponding grooves 122. Inoperation, rolls 302 and 303 intermesh such that the ridges 101 of oneroller extend into the grooves 122 or 112 of the other roller, the teeth111 of roller 302 extend into the grooves 122 of roller 303, and theteeth 121 of roller 303 extend into the grooves 112 of roller 302.

All or any one of rolls 301, 302 and 303 can be heated by means known inthe art such as by incorporating hot oil filled rollers orelectrically-heated rollers. Alternatively, both or either of the rollsmay be heated by surface convection, induction, or by surface radiation.

In another embodiment, the first and the second discrete features areformed simultaneously by feeding a composite 31, 41 or a laminate 61 ina machine direction into a nip nip that is formed between two rolls, therolls having surfaces wherein at least one of the two rolls has firstdiscrete feature forming elements on its surface and at least one of thetwo rolls has second discrete feature forming elements on its surface,and when the composite 41 or the laminate 61 is fed into the nip, thecomposite 41 or the laminate 61 is deformed. In another embodiment, whenone roller has first discrete feature forming elements on its surface,the other roller can have second discrete feature forming elements onits surface, causing features to be formed in opposite directions. Whenapertures as either first or second discrete features are formedaccording to the method disclosed in U.S. Pat. No. 5,628,097, thecomposite 31, 41 or the laminate 61 is weakened at a plurality oflocations by for example heat and/or pressure prior to being fed into anip formed between two rolls.

The rolls used in the apparatuses and methods described herein aretypically generally cylindrical. The term “generally cylindrical”, asused herein, encompasses rolls that are not only perfectly cylindrical,but also cylindrical rolls that may have elements on their surface. Theterm “generally cylindrical” also includes rolls that may have astep-down in diameter, such as on the surface of the roller near theends of the roller. It also includes ring rolls having meshing teeth.This can enable forming deformed elements of different heights inrespective zones of the same roller. The rolls are also typically rigid,that is, substantially non-deformable.

WO 2012/148935 discloses several mechanical deformation processes forforming discrete features such as an approach utilizing a single nipwith two rolls comprising discrete male forming elements wherein atleast one roller comprises two or more raised ridges, and anotherapproach comprising a multi-hit (multi-nip) configuration that enablescontrolled placement and orientation of multiple sets of features. Eachof these approaches may enable independent control of the featuresformed in a multi-layer structure, providing additional control over thefunction and aesthetics of the features. For example, this process couldprovide the ability to create multi-layer structures where some featureshave more layers through their thickness than other features.

In one embodiment, the first discrete feature forming elements or thesecond discrete feature forming elements can be heated.

In one embodiment when a plurality of the first and/or second discretefeatures are apertures, the first and/or the second discrete featureforming elements can comprise rounded teeth or triangular shaped teethdisclosed in WO 2005/13874. Alternatively, in the embodiment, the firstand/or the second discrete feature forming elements can comprise beingtapered from a base and a tip wherein the base of each tooth has across-sectional length dimension greater than a cross-sectional widthdimension, wherein each tooth is oriented such that the cross-sectionallength dimension of the tooth is disposed at an angle greater than zerorelative to a predominant molecular orientation of the polymer film asdescribed in WO 2010/90974.

In another embodiment, the first layer is polymer film having apertures.

In another embodiment, the first deformed composite 32, 42 the seconddeformed composite 43, the first deformed laminate 62, the seconddeformed laminate 63 may be ring rolled with intermeshing rolls afterforming the first or second discrete features, especially after formingapertures. Ring-rolling composites or laminates after forming discretefeatures, especially apertures, is expected to result in an increase inthe size of the apertures and increase in the air permeability of thefilm.

In another embodiment when a plurality of second discrete features aretufts, the first discrete feature forming elements can comprise aplurality of ridges and corresponding grooves which extend unbrokenabout the entire circumference of a roller which has the second discretefeature forming elements discloses in WO 2004/59061, and WO 2010/117636.The tufts may comprise a plurality of tufted fibers being integralextensions of the nonwoven. In another embodiment when the second layeris a nonwoven, and a plurality of second discrete features are tufts, atleast part of the distal portion of each of the tufts is covered by acap, each cap being an integral extension of the first layer extendingover the distal portion of a discrete tuft.

Provision of a Colored Region on Colored Sheet

In the present invention, a first colored region on a colored sheet webcan be provided by various methods and apparatus well known to thoseskilled in the art such as lithographic, screen printing, flexographic,gravure ink jet printing techniques or a method of producing colorchange using an activatable colorant, and virtually any graphic in anycolor or color combination can be rendered on the colored sheet web.Patents disclosing such methods include: U.S. Pat. No. 7,736,688disclosing flexographic printing; WO 2011/25486 disclosing a method ofmanufacturing an absorbent article having two colored regions and amethod of color measurement; and WO2011/133464 and WO2011/133462disclosing a method of producing color change on a web using anactivatable colorant.

Supplying and Integration of Colored Sheet Web

Hereinafter in this section of Supplying and Integration of Coloredsheet web, a deformed composite collectively denotes a first deformedcomposite of a polymer film and a nonwoven when a second discretefeatures are not formed and a second deformed composite of a polymerfilm and a nonwoven when a second discrete features are formed, and adeformed laminate collectively denotes a first deformed laminate of apolymer film and a nonwoven when a second discrete features are notformed and a second deformed laminate of a polymer film and a nonwovenwhen a second discrete features are formed.

A colored sheet web having a first colored region is introduced by anapparatus, such as a roller, onto the second layer side of the deformedcomposite or the deformed laminate; and the colored sheet web, and thedeformed composite or the deformed laminate are both moving in a machinedirection. The colored sheet web can be introduced onto the deformedcomposite or the the deformed laminate as either a continuous layer or adiscrete sheet cut before supplied onto the deformed composite into apredetermined size and shape. A discrete sheet of the colored sheet webhaving a first colored region can be prepared by printing a plurality offirst colored regions on a continuous liquid pervious colored sheet weband cutting the continuous liquid pervious colored sheet web intodiscrete sheets in a predetermined shape and size using a cutting meanswell known to those skilled in the art. The exact dimensions of the sizeand shape of the discrete sheets may be determined depending on type ofan absorbent article. In one example, the colored sheet comprising acolored sheet web is in size and shape which is shorter in length thanthe final length of an absorbent article such that fluid cannot betransported or wicked to the end of the article. In another embodiment,the colored sheet comprising a colored sheet web extends to theperiphery of the topsheet so that the colored sheet web layer underliesthe topsheet on the entire inner surface of the topsheet. In the methodaccording to the present invention, a colored sheet web and a compositeof the first and second layers can be integrated by various methods andapparatus known to those skilled in the art. For examples, theintegration can be carried out by a process selected from the groupconsisting of cold pressure bonding, heated pressure bonding, ultrasonicbonding, gluing and combinations thereof. Patents disclosing suchmethods include: U.S. Pat. Nos. 4,854,984 and 4,919,738 for coldpressure bonding.

In one embodiment, a colored sheet web having a first colored region ina predetermined size and shape, and a deformed composite or a deformedlaminate can be integrated by heated pressure bonding method comprisingforwarding a composite of the colored sheet web and the deformedcomposite or the deformed laminate through a generally cylindricalpattern defining roller and a mating anvil roller. The generallycylindrical pattern defining roller and mating anvil roller may berotated at matched speeds or at differing speeds to one another.

Supplying and Integrating Backsheet Web

A backsheet web can be supplied by an apparatus such as an adhesivebonding roller or thermal sealing roller onto a colored sheet web sideof the integrated composite 34, 44, or the integrated laminate 64 whichare moving in a machine direction to form an absorbent article assembly36, 46, 66. When an absorbent core is optionally provided onto theintegrated composite or integrated laminate, the backsheet web can beintroduced onto an absorbent core side.

The backsheet web is integrated to the integrated composite orintegrated laminate so that in an absorbent article a backsheet ispreferentially peripherally joined with a topsheet using knowntechniques, either entirely so that the entire perimeter of theabsorbent article is circumscribed by such joinder or are partiallyperipherally joined at the perimeter.

Severing Absorbent Article Assembly

The absorbent article assembly is severed or cut using by a cutting unitconventional in the technical area of absorbent article fabrication,such as flex knife, rotary die, ultrasonic, water jet, or laser cutting,into individual absorbent articles to have a predetermined size andshape.

Optional Steps

Registration/Phasing

Absorbent articles comprise multiple functional and/or aestheticcomponents including compositional elements such as a topsheet, abacksheet and optionally secondary topsheet and an absorbent core, anddesign elements such as colored regions, discrete features formed on atopsheet, and optionally channels and a logo. During the manufacturingof absorbent articles, the position of components of article in eachstep of the manufacturing process may affect the overall quality of thearticles and the acceptance of the articles by consumers, as consumersoften desire consistency in the configuration of purchased goods forboth functional and aesthetic reasons. For example, locations of thefirst discrete features, the second discrete feature, the first coloredregion and/or the second colored region need to be controlled asdesigned to secure best functional and aesthetic goods. To ensureconsistency throughout the manufacturing process, components must bepositioned uniformly.

Various methods and systems for inspecting the locations of selectedcomponents of an absorbent article during a manufacturing process havebeen known. Patents disclosing such methods and systems include: U.S.Pat. No. 5,359,525; EP 2090 951 A1; and WO 2012/161709 disclosing systemand method of the automated regulation of production lines. In a methodaccording to the present invention, a phasing can be conducted inbetween two consecutive steps to determine and control position of atleast one component, and may be carried out at least once.

Formation of Apertures in Web

In one embodiment, a method according to the present invention mayfurther comprise a step of forming a plurality of apertures on a firstlayer prior to forming a composite of the first layer and a secondlayer. In another embodiment, a method according to the presentinvention, when the second layer is a polymer film, further comprises astep of forming a plurality of apertures on the polymer film prior toforming a composite of the first layer and a second layer. Aperturingmethods described in the section of “Formation of First DiscreteFeatures and Optional Second Discrete Features” above are applicable foraperture formation on the polymer film.

Formation of a Plurality of Discrete Extended Elements

A method according to the present invention optionally comprises a stepof forming a plurality of discrete extended elements on a first layer, acomposite of a first layer and a second layer, or a laminate comprisinga first layer and a second layer when at least the first layer is apolymer film.

Hereinafter in this section of Formation of a Plurality of DiscreteExtended Elements, a first layer, a composite a first layer and a secondlayer and a laminate comprising a first layer and a second layer arecollectively denoted as a precursor web. It can be beneficial for theprecursor web to have a textured surface by having a plurality ofdiscrete extended elements which can provide the surface of the polymerfilm with a desirable feel, visual impression, and/or audibleimpression.

A plurality of discrete extended elements can be made in a vacuumforming process, a hydroforming process, a high static pressure formingprocess, a solid state deformation process in mated forming structures,or methods using a forming structure and a compliant substrate. With atypical vacuum forming process, a precursor web is heated and placedover a forming structure. Then a vacuum forces the precursor web toconform to the texture of the forming structure. The resulting web hastexture that can provide a soft and silky tactile impression, dependingupon the texture of the forming structure and degree of conformation.With a typical hydroforming process, a precursor web is placed over aforming structure and high pressure and high temperature water jetsforce the precursor web to conform to the texture of the formingstructure. A high static pressure forming process employs a highpressure gas to deform the precursor web to the texture of a formingstructure as disclosed in WO 10/105002, WO 10/105017 and WO 11/112213,while solid state deformation conveys the web between mating formingstructures as disclosed in WO 12/148936, or uses a compliant substrateto impress the discrete extended elements into the precursor web asdisclosed in WO 10/105009 and WO 10/105019.

A plurality of discrete extended elements in the present invention,especially when the first layer is a polymer film, comprise openproximal ends, open or closed distal ends, and sidewalls, wherein thediscrete extended elements comprise thinned portions at the distal endsof the discrete extended elements and/or along the sidewalls of thediscrete extended elements, and wherein (a) the discrete extendedelements have a diameter of less than about 500 microns, (b) thediscrete extended elements have an aspect ratio of at least about 0.2,and/or (c) the polymer film comprises at least about 95 discreteextended elements per square centimeter.

In an embodiment, a plurality of discrete extended elements can beformed by a process comprising the steps of: i) providing a formingstructure comprising a plurality of discrete protruded elements andlands completely surrounding the discrete protruded elements; ii)providing a compliant substrate; iii) providing a precursor web betweenthe compliant substrate and the forming structure; and iv) providingpressure between the compliant substrate and the forming structuresufficient to conform the precursor web to the discrete protrudedelements of the forming structure to form the embossed web.

In another embodiment, a plurality of discrete extended elements can beformed by a process comprising the steps of: i) feeding a precursor webbetween a static gas pressure plenum and a forming structure comprisinga plurality of discrete protruded elements, the discrete protrudedelements having a height of at least substantially equal to a thicknessof the precursor web; and ii) applying pressure from the static gaspressure plenum against the precursor web opposite the forming structurecreating a pressure differential across the precursor web sufficient toconform the precursor web to the discrete protruded elements of theforming structure.

In another embodiment, a plurality of discrete extended elements can beformed by a process comprising the steps of: i) feeding a precursor webbetween a static gas pressure plenum and a forming structure comprisinga plurality of discrete apertures, discrete depressions, or combinationsthereof, the apertures or depressions having a depth of at leastsubstantially equal to a thickness of the precursor web; and ii)applying pressure from the static gas pressure plenum against theprecursor web opposite the forming structure creating a pressuredifferential across the precursor web sufficient to force the precursorweb into the apertures or depressions of the forming structure, therebyforming the precursor web comprising a plurality of discrete extendedelements.

In another embodiment, a plurality of discrete extended elements can beformed by a process comprising the steps of: i) providing a precursorweb, ii) providing a pair of mated forming structures, including a firstforming structure and a second forming structure, wherein at least thefirst forming structure comprises voids, and wherein at least the secondforming structure comprises protrusions; and iii) moving the web througha deformation zone between the mated forming structures, wherein thevoids of the first forming structure engage with the protrusions of thesecond forming structure at an engagement position.

Provision of a Second Colored Region

A method according to the present invention optionally comprises a stepof providing a second colored region on the polymer film or the nonwovenprior to formation of the first discrete features. The second coloredregion can be provided either side of the polymer film or the nonwoven.

Coloration methods described in the section of Provision of a ColoredRegion on Colored Sheet above are applicable for coloration of thesecond colored region.

Introduction of Absorbent Core

A method according to the present invention optionally further comprisesa step of supplying a precursor absorbent core to a colored sheet webside of an integrated composite 34, 44, or an integrated laminate 64,moving in a machine direction. The absorbent core can be supplied as apreformed core. In one embodiment, the absorbent core is cut in apredetermined size and shape before being provided onto the coloredsheet web side of the integrated composite. An absorbent core can beintegrated to the integrated composite or an integrated laminate byvarious methods and apparatus known in the art such as cold pressurebonding, heated pressure bonding, ultrasonic bonding, gluing andcombinations thereof. In one embodiment, an absorbent core can beintegrated to form the core layered composite by gluing.

Application of Lotion Composition

Treatments of an absorbent article with lotion have been proposed toprovide skin health benefits and to allow fluid to be absorbed into thearticle. To provide an absorbent article treated with a lotion, a methodof the present invention may further comprise a step of applying alotion composition to at least a portion of a topsheet, the innersurface of the backsheet, and/or any substrate (or surface thereof)disposed between the topsheet and the backsheet such as a secondarytopsheet and an absorbent core. The lotion composition can be a liquid,a solid or a semi-solid at room temperature, and comprise at least oneskin benefit agent. The lotion composition can be applied in any knownmanner, in any known pattern, and to any known portion of the absorbentarticle, as is well known in the art of lotioned absorbent articles. Forexample, the lotion composition can be applied in a pattern of generallyparallel stripes or bands. The lotion composition can be a lotioncoating on any part of the article, and on either side of any layer,such as upper surfaces, or lower surfaces. In one embodiment, a lotioncomposition can be disposed on the inner surface of the topsheet bydisposing the lotion composition on at least one of a lower side of afirst layer, a upper side and a lower side of a second layer. The lotioncan be applied prior to the first discrete forming step, after the firstdiscrete forming step and/or after the second discrete forming step.

Application of Odor Control Composition

A method of the present invention may further comprise a step ofapplying an odor control composition. Use of a fragrance compositionand/or an odor control composition in absorbent articles has beenproposed for controlling and reducing malodors in the articles. Ingeneral, suitable components for odor control compositions includereactive components. Reactive components include components that canreact with malodors, such as ammonia-based malodors or sulphur-basedmalodors (i.e. “malodor reactive components”), and components that maskmalodors and/or react with receptors of the nose to block the perceptionof malodor by the nose of a consumer (i.e. “malodor maskingcomponents”). Suitable reactive components are described, for example,in US 2008/0071238 A1 and WO 07/113778, and suitable masking componentsare described, for example, in WO 08/114226.

An odor control composition may be applied on or within a layer of anabsorbent article in any known manner, in any known pattern, and to anyknown portion of the absorbent article, as is well known in the art ofabsorbent articles. This means that, since the absorbent article isconstituted by a series of layers, the odor control composition isapplied onto one of the surfaces of these layers. An odor controlcomposition can be applied onto the surface of application with anypossible application pattern. In some cases it is possible that the odorcontrol composition is applied on more than one layer within thearticle.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for fabricating an absorbent article,the absorbent article comprising a liquid permeable topsheet comprisinga first layer, a second layer, a plurality of first discrete features,and a plurality of second discrete features; a colored sheet comprisinga colored sheet web having a first colored region; and a liquidimpermeable backsheet comprising a backsheet web, the absorbent articlehaving a body-facing surface comprising the first layer and agarment-facing surface positioned opposite to the body-facing surface,the method comprising the steps of: a) supplying the second layer ontothe first layer to form a composite of the first layer and the secondlayer; b) forming the plurality of first discrete features on thecomposite of the first layer and the second layer via a first nipdefined between a first roll and a second roll, wherein at least one ofthe first roll and the second roll comprises first discrete featureforming elements; c) forming the plurality of second discrete featureson the composite of the first layer and the second layer via a secondnip defined between the second roll and a third roll to form a deformedcomposite, wherein at least one of the second roll and the third rollcomprises second discrete feature forming elements; d) supplying thecolored sheet web having the first colored region onto the second layerside of the deformed composite, and integrating the deformed compositeand the colored sheet web to form an integrated composite; e) supplyingthe backsheet web onto the colored sheet web side of the integratedcomposite, and integrating the integrated composite and the backsheetweb to form an absorbent article assembly; and f) severing the absorbentarticle assembly into individual absorbent articles, wherein theabsorbent article has a background region, wherein the background regionand the first colored region are viewable from the body facing surface,and wherein the first colored region differs in color from thebackground region.
 2. The method according to claim 1, wherein the firstlayer in step a) comprises a plurality of discrete extended elements,wherein the discrete extended elements comprise open proximal ends, openor closed distal ends, and sidewalls, wherein the discrete extendedelements comprise thinned portions at the distal ends of the discreteextended elements and/or along the sidewalls of the discrete extendedelements, and wherein a) the discrete extended elements have a diameterof less than about 500 microns; b) the discrete extended elements havean aspect ratio of at least about 0.2; or c) the first layer comprisesat least about 95 discrete extended elements per square centimeter. 3.The method according to claim 2, wherein the first layer in step a)further comprises apertures wherein the apertures have a diameter biggerthan that of the plurality of discrete extended elements.
 4. The methodaccording to claim 3, further comprising a step of providing the firstlayer with a second colored region by a second coloration techniquecarried out prior to step d), wherein the first colored region and thesecond colored region differ in color from the background region.
 5. Themethod according to claim 3, wherein the first discrete features arefeatures selected from the group consisting of apertures, protrusions,depressions, tufts and combinations thereof.
 6. The method according toclaim 3, further comprising a step of determining and controllingpositions of at least one component of the absorbent article at leastonce during steps a) through f).
 7. The method according to claim 3,wherein the first layer and second layer are integrated prior to step b)by an integration process selected from the group consisting of coldpressure bonding, heated pressure bonding, ultrasonic bonding, gluingand combinations thereof.
 8. The method according to claim 1, furthercomprising a step of providing at least one of the first layer and thesecond layer with a second colored region by a second colorationtechnique carried out prior to steps b) and c), wherein the firstcolored region and the second colored region differ in color from thebackground region.
 9. The method according to claim 1, wherein the firstlayer and second layer are integrated prior to step b) by an integrationprocess selected from the group consisting of cold pressure bonding,heated pressure bonding, ultrasonic bonding, gluing and combinationsthereof.
 10. The method according to claim 1, wherein the plurality offirst discrete features formed in step a) is apertures and formed by amethod comprising the steps of: 1) weakening the composite of the firstlayer and the second layer at a plurality of locations to create aplurality of weakened, melt-stabilized locations; and 2) applying atensioning force to the composite to cause the composite to rupture atthe plurality of weakened, melt-stabilized locations creating aplurality of apertures in the composite coincident with the plurality ofweakened, melt-stabilized locations.
 11. The method according to claim10, wherein the composite is weakened by at least one means selectedfrom heat, pressure and a combination thereof.
 12. The method accordingto claim 1, wherein the first layer is selected from a group consistingof polymer film, a nonwoven and a combination thereof, and the secondlayer is selected from a group consisting of a polymer film, a nonwovenand a combination thereof.
 13. A method for fabricating an absorbentarticle, the absorbent article comprising a liquid permeable topsheetcomprising a first layer, a second layer, a plurality of first discretefeatures, and a plurality of second discrete features that are differentfrom the first discrete features; a colored sheet comprising a coloredsheet web having a first colored region; and a liquid impermeablebacksheet comprising a backsheet web, the absorbent article having abody-facing surface and a garment-facing surface positioned opposite tothe body-facing surface, the method comprising the steps of: a) formingthe plurality of first discrete features on a laminate comprising thefirst layer and the second layer; b) forming the plurality of seconddiscrete features on the laminate comprising the first layer and thesecond layer to form a deformed laminate; c) supplying the colored sheetweb having the first colored region onto the second layer side of thedeformed laminate, and integrating the deformed laminate and the coloredsheet web to form an integrated laminate; d) supplying the backsheet webonto the colored sheet web side of the integrated laminate, andintegrating the integrated laminate and the backsheet web to form anabsorbent article assembly; and e) severing the absorbent articleassembly into individual absorbent articles, wherein steps a)-d) areconducted in a continuous operation, wherein the absorbent article has abackground region, wherein the background region and the first coloredregion are viewable from the body facing surface, and wherein the firstcolored region differs in color from the background region.
 14. Themethod according to claim 13, wherein the steps a) and b) are carriedout simultaneously.
 15. The method according to claim 13, furthercomprising a step of providing the first layer with a second coloredregion by a second coloration technique carried out prior to step a) orstep b), wherein the first colored region and the second colored regiondiffer in color from the background region.
 16. The method according toclaim 13, wherein the first discrete features are features selected fromthe group consisting of apertures, protrusions, depressions, tufts andcombinations thereof, and the second discrete feature are featuresselected from the group consisting of apertures, protrusions,depressions, tufts and combinations thereof.
 17. The method according toclaim 13, further comprising a step of determining and controllingpositions of at least one component of the absorbent article at leastonce between steps (a) through (d).
 18. The method according to claim13, wherein the plurality of first discrete features formed in step a)is formed by a method comprising the steps of: 1) weakening the laminatecomprising the first layer and the second layer at a plurality oflocations to create a plurality of weakened, melt-stabilized locations;and 2) applying a tensioning force to the laminate to cause the laminateto rupture at the plurality of weakened, melt-stabilized locationscreating a plurality of apertures in the laminate coincident with theplurality of weakened, melt-stabilized locations.
 19. The methodaccording to claim 18, wherein the laminate is weakened by at least onemeans selected from heat, pressure and a combination thereof.
 20. Themethod according to claim 13, wherein the first layer is selected from agroup consisting of polymer film, a nonwoven and a combination thereof,and the second layer is selected from a group consisting of a polymerfilm, a nonwoven and a combination thereof.
 21. A method for fabricatingan absorbent article, the absorbent article comprising a liquidpermeable topsheet comprising a first layer, a second layer, a pluralityof first discrete features, a plurality of second discrete features thatare different from the first discrete features, and a topsheet coloredregion; a colored sheet comprising a colored sheet web comprising acolored sheet colored region; a liquid impermeable backsheet web, theabsorbent article comprising a body-facing surface comprising the firstlayer and a garment-facing surface comprising the liquid impermeablebacksheet web, the method comprising the step of: a. supplying the firstlayer having a first surface and a second surface; b. adding color tothe second surface of the first layer to define the topsheet coloredregion; c. following step b), overlaying the second layer onto thesecond surface of the first layer to form a topsheet composite of thefirst layer and the second layer; d. following step c), forming theplurality of first discrete features in the topsheet composite; e.concurrently with or following step d), forming the plurality of seconddiscrete features in the topsheet composite; f. following step e),supplying the colored sheet web; g. following step f), adding color tothe colored sheet web to define the colored sheet colored region; h.following step g), integrating the colored sheet web and the topsheetcomposite; i. following step h), adding an absorbent core to theintegrated colored sheet web and topsheet composite; j. following stepi), overlaying the liquid impermeable backsheet web; k. wherein stepsa)-j) are conducted in a continuous operation, and l. wherein both thetopsheet colored region and the colored sheet colored region areviewable from the body-facing surface of the article.
 22. The methodaccording to claim 21, wherein step d) comprises imparting a pattern ofweakened, melt-stabilized locations.
 23. The method according to claim21, wherein step e) comprises the creation of fiber tufts.
 24. Themethod according to claim 21, wherein the first discrete features aresubstantially confined to a plane of the topsheet composite, and whereinthe second discrete features at least in part extend from the plane ofthe topsheet composite.
 25. The method according to claim 21, whereinthe first discrete features comprise apertures and the second discretefeatures comprise fiber tufts.
 26. The method according to claim 21,wherein the first layer is a polymer film and wherein the second layeris a nonwoven.
 27. The method according to claim 21, wherein the firstlayer is a nonwoven and the second layer is a nonwoven.